Pressure Relief Devices

Pressure Relief Devices

Authors: Mohammad Malek

Published: October 2005

eISBN: 9780071589062 0071589066 | ISBN: 9780071455374

Contents

Preface

Chapter 1. Fundamentals of Pressure Relief Devices

1.1 Brief History

1.2 Pressure Vessels

1.2.1 Boiler accidents

1.2.2 Pressure vessel accidents

1.3 Pressure Relief Devices

1.4 Reclosing-Type Pressure Relief Devices

1.4.1 Pressure relief valves

1.4.2 Safety valves

1.4.3 Relief valves

1.4.4 Safety relief valves

1.5 Pressure Vacuum Relief Valves

1.5.1 Pressure vacuum vent valves

1.5.2 Pressure relief valves

1.5.3 Vacuum relief valves

1.6 Nonreclosing Pressure Relief Devices

1.6.1 Rupture disks

1.6.2 Breaking pin devices

1.6.3 Buckling pin devices

1.6.4 Shear pin devices

1.6.5 Fusible plug devices

1.7 Codes and Standards

1.7.1 U.S.codes

1.7.2 International codes

1.8 Jurisdictional Authority

Chapter 2. Pressure Relief Valves

2.1 Safety Relief Valves

2.1.1 Conventional pressure relief valves

2.1.2 Pilot-operated pressure relief valves

2.1.3 Balanced bellows pressure relief valves

2.1.4 Power-actuated pressure relief valves

2.1.5 Temperature-actuated pressure relief valves

2.2 Relief Valves

2.3 Safety Valves

2.4 Major Components

2.5 Accessories

2.6 Specifications

2.6.1 How to order a conventional pressure relief valve

2.6.2 Specification sheets

Chapter 3. Safety Valves

3.1 Working Principle

3.2 Classification of Safety Valves

3.2.1 Classification based on actuation

3.2.2 Classification based on lift

3.2.3 Classification based on seat design

3.2.4 Classification based on type of lever

3.2.5 Classification based on bonnet design

3.3 Major Components

3.4 Accessories

3.5 Safety Valve Locations

3.5.1 Pressure-reducing station

3.5.2 Pharmaceutical factory with jacketed pans

3.6 Specifications

3.6.1 Specification sheet

3.6.2 Specifying a safety valve

Chapter 4. Rupture Disks

4.1 Brief History

4.2 Working Principle

4.3 Application of Rupture Disks

4.3.1 Primary relief

4.3.2 Secondary relief

4.3.3 Combination relief

4.4 Types of Rupture Disks

4.4.1 Conventional rupture disks

4.4.2 Scored tension-loaded rupture disks

4.4.3 Composite rupture disks

4.4.4 Reverse-acting rupture disks

4.4.5 Graphite rupture disks

4.5 Major Components

4.6 Accessories

4.7 Specifications

4.7.1 How to specify a rupture disk

4.7.2 Specification sheet

4.8 Rupture Pin Relief Valves

4.8.1 Comparison of rupture pins and rupture disks

4.9 Buckling Pin Relief Valves

4.9.1 Valve characteristics

4.9.2 Specifications

Chapter 5. Materials

5.1 Pressure Relief Valves

5.1.1 Materials

5.1.2 Bill of materials

5.1.3 Material selection

5.2 Rupture Disks

5.2.1 Bill of materials

5.2.2 Material selection

Chapter 6. Design

6.1 Fundamentals of Design

6.1.1 Seat disk lift

6.1.2 Back pressure

6.1.3 Bonnet

6.1.4 Valve nozzle

6.2 Design Factors

6.2.1 Flow area

6.2.2 Curtain area

6.2.3 Discharge area

6.2.4 Other design factors

6.3 Pressure Requirements

6.3.1 System pressures

6.3.2 Relieving device pressures

6.4 Design Considerations

6.5 Design of Parts

6.5.1 Body

6.5.2 Bonnet

6.5.3 Nozzle

6.5.4 Disk

6.5.5 Spindle

6.5.6 Adjusting ring

6.5.7 Adjusting screw

6.5.8 Huddling chamber

6.5.9 Spring

6.6 Testing and Marking

6.6.1 Hydrostatic test

6.6.2 Marking

6.7 Rupture Disks

6.7.1 Basic design

6.7.2 Operating ratios

6.7.3 Pressure-level relationship

6.7.4 Certified K[sub(R)] and MNFA

Chapter 7. Manufacturing

7.1 Manufacture of Pressure Relief Valves

7.1.1 Test laboratories

7.1.2 Capacity certification

7.1.3 Capacity certification in combination with rupture disks

7.1.4 Testing by manufacturers

7.1.5 Inspection and stamping

7.1.6 Manufacturer's data reports

7.2 Manufacture of Rupture Disks

7.2.1 Manufacturing ranges

7.2.2 Rupture tolerances

7.2.3 Capacity certification

7.2.4 Production testing

7.2.5 Marking

7.2.6 Manufacturer's data reports

Chapter 8. Sizing and Selection

8.1 Pressure Relief Valves

8.1.1 Valve sizes

8.1.2 Required sizing data

8.1.3 API sizing

8.1.4 Sizing for vapors and gases

8.1.5 Sizing for liquids

8.1.6 Sizing for air

8.1.7 Sizing multiple valves

8.1.8 Saturated-water valve sizing

8.1.9 RRV and rupture disk combinations

8.1.10 Sizing for thermal expansion of trapped liquids

8.1.11 Sizing for mixed phases

8.2 Rupture Disks

8.2.1 Sizing method

Chapter 9. Safety Valves for Power Boilers

9.1 Operational Characteristics

9.2 Code References

9.3 Design Requirements

9.3.1 Mechanical requirements

9.3.2 Material selection

9.3.3 Boiler safety valves

9.3.4 Superheater safety valves

9.3.5 Reheater safety valves

9.3.6 Organic fluid vaporizer safety valves

9.4 Capacity Requirements

9.4.1 Relieving capacity

9.4.2 Capacity checking

9.4.3 Capacity certification

9.5 Testing by Manufacturers

9.6 Inspection and Stamping

9.7 Certificate of Conformance

9.8 Operation

9.9 Selection of Safety Valves

9.9.1 Ordering information

9.9.2 Specifying safety valves

Chapter 10. Pressure Relief Valves for Heating Boilers

10.1 Code References

10.2 Design Requirements

10.2.1 Safety valve requirements for steam boilers

10.2.2 Safety relief valve requirements for hot water boilers

10.2.3 Safety and safety relief valves for tanks and heat exchangers

10.2.4 T&P safety relief valves for hot water heaters

10.2.5 Mechanical requirements

10.2.6 Material selection

10.2.7 Locations

10.3 Manufacture and Inspection

10.3.1 Valve markings

10.4 Manufacturer's Testing

10.5 Capacity Requirements

10.5.1 Calculation of capacity to be stamped on valves

10.5.2 Fluid medium for tests

10.5.3 Capacity tests of T&P safety relief valves

10.5.4 Capacity tests for safety and safety relief valves

10.5.5 Test record data sheets

Chapter 11. Pressure Relief Devices for Pressure Vessels

11.1 Introduction

11.1.1 Types of pressure vessels

11.1.2 Pressure vessel codes

11.1.3 Pressure relief devices

11.2 Pressure Relief Valves

11.2.1 Operational requirements

11.2.2 Code references

11.2.3 Design requirements

11.2.4 Capacity certification

11.2.5 Testing by manufacturers

11.2.6 Inspection and certification

11.3 Rupture Disks

11.3.1 Operational characteristics

11.3.2 Code references

11.3.3 Design requirements

11.3.4 Capacity certification

11.3.5 Testing by manufacturers

11.3.6 Inspection and certification

Chapter 12. Pressure Relief Devices for Nuclear Systems

12.1 Nuclear Reactors

12.1.1 Boiling-water reactors

12.1.2 Pressurized-water reactors

12.2 Overpressure Protection Reports

12.2.1 Content of report

12.2.2 Certification of report

12.2.3 Review of report

12.2.4 Filing of report

12.3 Code Requirements

12.4 Relieving Capacity

12.5 Operating Requirements

12.6 Capacity Certification for Pressure Relief Valves

12.7 Marking, Stamping, and Data Reports

12.7.1 Pressure relief valves

12.7.2 Rupture disks

Chapter 13. Pressure Relief Devices for Transport Tanks

13.1 Classes of Vessels

13.2 Pressure Relief Devices

13.2.1 Determining pressure relief requirements

13.2.2 Code references

13.2.3 Installation requirements

13.3 Requirements for Pressure Relief Valves

13.3.1 Types of pressure relief valves

13.3.2 Design requirements

13.3.3 Materials requirements

13.3.4 Manufacturing

13.3.5 Marking and certification

13.3.6 Production testing

13.4 Requirements for Rupture Disks

13.4.1 Design requirements

13.4.2 Materials requirements

13.4.3 Manufacturing

13.4.4 Marking and certification

13.4.5 Production testing

13.4.6 Installation requirements

13.5 Requirements for Breaking Pin Devices

Chapter 14. Pressure Relief Devices for Petroleum Industries

14.1 Refining Operations

14.2 Protection of Petroleum Equipment

14.3 Protection of Tanks

14.4 Fire Sizing

14.4.1 Fire sizing standards

14.4.2 Fire sizing for liquid hydrocarbons

14.4.3 Fire sizing for vessels containing gases

14.5 Seat Tightness Test

14.5.1 Testing with air

14.5.2 Testing with steam

14.5.3 Testing with water

Chapter 15. Installation

15.1 Installation of Pressure Relief Valves

15.1.1 Preinstallation handling and testing

15.1.2 Inlet piping

15.1.3 Discharge piping

15.1.4 Power piping systems

15.1.5 Isolation valves

15.1.6 Vent piping

15.1.7 Drain piping

15.1.8 Bolting and gasketing

15.2 Installation of Rupture Disks

15.2.1 Preparation for installation

15.5.2 Inspection

15.2.3 Installation guidelines

Chapter 16. Operation

16.1 General Guidelines for Operation

16.2 Visual Examination

16.3 Safety Valve Operation

16.3.1 Hand lift operation

16.3.2 Operation testing

16.3.3 Precaution for hydrostatic test

16.4 Safety Relief Valve Operation

16.4.1 Valve tightness test

16.4.2 Lift and blowdown

16.4.3 Testing

16.5 Operator's Responsibilities

Chapter 17. Maintenance

17.1 Valve Specification Records

17.2 Maintenance Procedures

17.2.1 Pretest

17.2.2 Disassembly

17.2.3 Repairs

17.2.4 Assembly

17.2.5 Valve testing

17.3 Types of Maintenance

17.3.1 Routine maintenance

17.3.2 In-line maintenance

17.3.3 Preventive maintenance

17.4 Testing

17.4.1 Setting

17.4.2 Blowdown adjustment

17.4.3 Seat tightness test

17.5 Causes of Improper Performance

17.5.1 Rough handling

17.5.2 Corrosion

17.5.3 Damaged seating surfaces

17.5.4 Failed springs

17.5.5 Improper setting and adjustment

17.5.6 Plugging and sticking

17.5.7 Misapplication of materials

17.5.8 Improper discharge piping test

17.6 Troubleshooting

17.7 Spare Parts

17.8 Storage

Chapter 18. Inspection

18.1 Authorized Inspectors

18.2 Types of Inspections

18.2.1 Inspection of new installations

18.2.2 Routine inspection

18.2.3 Shop inspection

18.2.4 Visual on-stream inspection

18.2.5 In-service testing

18.2.6 Unscheduled inspection

18.3 Safety Valve Inspection

18.4 Safety Relief Valve Inspection

18.5 Rupture Disk Inspection

18.6 Records and Reports

Chapter 19. Repairs

19.1 Repairers

19.2 Repair of Pressure Relief Valves

19.2.1 Visual inspection as received

19.2.2 Preliminary test as received

19.2.3 Disassembly

19.2.4 Cleaning parts

19.2.5 Inspection

19.2.6 Machining

19.2.7 Lapping

19.2.8 Adjusting rings

19.2.9 Bearing points

19.2.10 Assembly

19.2.11 Testing

19.2.12 Sealing

19.3 Repair Nameplates

19.4 Documentation

Chapter 20. Shop Testing

20.1 Test Media

20.1.1 Testing with air

20.1.2 Testing with nitrogen

20.1.3 Testing with water

20.1.4 Testing with steam

20.2 Test Stands

20.2.1 Test stand with air system

20.2.2 Multipurpose test stand

20.2.3 Portable tester

20.3 Testing

20.3.1 Set pressure

20.3.2 Blowdown

20.3.3 Seat tightness test

20.4 Test Reports

20.5 Rupture Disk Testers

Chapter 21. Terminology

21.1 Terminology for Pressure Relief Valves

21.2 Terminology for Rupture Disks

Appendix A. 1914 ASME Boiler Code

Appendix B. Spring-Loaded Pressure Relief Valve Specification Sheet

Appendix C. Pilot-Operated Pressure Relief Valve Specification Sheet

Appendix D. Rupture Disk Specification Sheet

Appendix E. ASME Application for Accreditation

Appendix F. ASME-Accredited Testing Laboratories

Appendix G. Physical Properties of Gas or Vapor

Appendix H. Superheat Correction Factor

Appendix I. Dimensions of Flanges

Appendix J. Pipe Data

Appendix K. Manufacturer's Data Report Form NV-1

Appendix L. Corrosion Resistance Guide

Appendix M. Water Saturation Pressure and Temperature

Appendix N. Value of Coefficient C

Appendix O. Unit Conversions

Bibliography

Index